US5108974A - Preparation of vanadium-phosophorus-oxide catalyst precursor - Google Patents

Preparation of vanadium-phosophorus-oxide catalyst precursor Download PDF

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Publication number
US5108974A
US5108974A US07/630,128 US63012890A US5108974A US 5108974 A US5108974 A US 5108974A US 63012890 A US63012890 A US 63012890A US 5108974 A US5108974 A US 5108974A
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yes
vanadium
phosphoric acid
catalyst precursor
oxide catalyst
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US07/630,128
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Gershon J. Davis
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Akzo NV
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Akzo NV
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    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C51/00Preparation of carboxylic acids or their salts, halides or anhydrides
    • C07C51/16Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation
    • C07C51/21Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen
    • C07C51/215Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen of saturated hydrocarbyl groups
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/002Mixed oxides other than spinels, e.g. perovskite
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/16Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J23/20Vanadium, niobium or tantalum
    • B01J23/22Vanadium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J27/00Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
    • B01J27/14Phosphorus; Compounds thereof
    • B01J27/186Phosphorus; Compounds thereof with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J27/195Phosphorus; Compounds thereof with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium with vanadium, niobium or tantalum
    • B01J27/198Vanadium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2523/00Constitutive chemical elements of heterogeneous catalysts

Definitions

  • VPO vanadium-phosphorus-oxide
  • the VPO catalyst precursor is ordinarily prepared by reducing vanadium pentoxide to vanadium tetraoxide with benzyl alcohol in an isobutanol solution.
  • the benzyl alcohol is oxidized to benzaldehyde.
  • the vanadium tetraoxide is then reacted with phosphoric acid in the presence of tetraethylorthosilicate to form the desired precursor phase having the formula (VO) 2 H 4 P 2 O 9 .
  • U.S. Pat. No. 4,632,916, at Col. 4, lines 1-6 indicates that various reductants can be employed including isobutanol, benzyl alcohol, and "reduced acids of phosphorus like H 3 PO 3 .
  • the isobutanol is oxidized more slowly to isobutyraldehyde, and butyral.
  • the foregoing procedure can be varied without using benzyl alcohol as the reductant if the vanadium pentoxide is reduced to the desired vanadium tetraoxide by being heated in the presence of a mixture of an alcohol and sufficient phosphoric acid. Even though the reduction of the pentoxide to the tetraoxide is achieved, the catalyst precursor that is precipitated in this system will not be crystalline (VO) 2 H 4 P 2 O 9 unless an alkyl silicate is present. When this specific compound is formed, rather than mixed vanadium phosphates, catalysts made from it give butane to maleic anhydride yields of up to about 90%, rather than 50% to 60%.
  • the reduction of the vanadium pentoxide is accomplished in accordance with the instant invention by heating the pentoxide in an appropriate solvent such as an alcohol, e.g., isobutanol, in the presence of a mixture of tetraethylorthosilicate and phosphoric acid.
  • an appropriate solvent such as an alcohol, e.g., isobutanol
  • the vanadium pentoxide is preferably in milled form, and the amount of phosphoric acid used should be sufficient (when taken with the later added amount of phosphoric) to give a P/V ratio in the final catalyst of from about 0.9:1 to about 1.3:1.0 as mentioned at Col. 4, lines 21-33, of U.S. Pat. No. 4,632,916.
  • the mixture of vanadium pentoxide, solvent, phosphoric acid, and tetraethylorthosilicate is preferably heated to reflux to achieve the desired degree of reduction.
  • V 2 O 5 Approximately 7 lbs of V 2 O 5 were finely ground through a model JT-6 Fitz mill using a 325 mesh screen with a canvass sock. The milling took place over a period of approximately 15 minutes and the V 2 O 5 was fed slowly with dry ice.
  • the resulting mixture was heated to reflux (about 100C) for approximately 13 hours. Then, the remainder of the 85% phosphoric acid (206 gm) was added. The resulting mixture was refluxed for 6-7 hours with a blue-green precipitate forming during this step.
  • the resulting reaction mixture was cooled down to close to room temperature and filtered through a 10-15 micron fritted glass filter with vacuum.
  • the product retained by the filter was washed twice with 250 ml of isobutanol and was dried in an oven at 145C and vacuum (20 mm Hg) for eight hours.
  • the product weighed about 490 gm and it was passed through a 100 mesh screen to form a more uniform particle size.
  • the product was confirmed by X-ray diffraction to be a (VO) 2 H 4 P 2 O 9 catalyst precursor for a vanadium-phosphorus mixed oxide catalyst.
  • Example 1 A series of variations were made in the procedure of Example 1 where certain reagents were either present or absent or were changed in some manner.
  • the X-ray diffraction pattern of the resulting product either conformed to that of (VO) 2 H 4 P 2 O 9 ("OK”) or did not ("NG").

Abstract

Vanadium pentoxide can be reduced to the +4 oxidation state from the +5 state, in the manufacture of vanadium-phosphorus-oxide catalyst precursor, (VO)2 H4 P2 O9, by using phosphoric acid as the reducing agent rather than benzyl alcohol. Use of an alkyl silicate with the phosphoric acid insures the correct crystalline species, (VO)2 H4 P2 O9, as indicated by X-ray diffraction.

Description

BACKGROUND OF THE INVENTION
It is well known in the art to synthesize vanadium-phosphorus-oxide (VPO) catalysts for the selective oxidation of C4 hydrocarbons to maleic anhydride. A recent article which affords an overview of this area of technology is H. S. Horowitz et al., Applied Catalysis, 38 (1988) 193-210 and U.S. Pat. No. 4,677,084 to H. E. Bergna which are each incorporated herein in their entirety.
The VPO catalyst precursor is ordinarily prepared by reducing vanadium pentoxide to vanadium tetraoxide with benzyl alcohol in an isobutanol solution. The benzyl alcohol is oxidized to benzaldehyde. The vanadium tetraoxide is then reacted with phosphoric acid in the presence of tetraethylorthosilicate to form the desired precursor phase having the formula (VO)2 H4 P2 O9. U.S. Pat. No. 4,632,916, at Col. 4, lines 1-6 indicates that various reductants can be employed including isobutanol, benzyl alcohol, and "reduced acids of phosphorus like H3 PO3. In the case of using isobutanol and benzyl alcohol, the isobutanol is oxidized more slowly to isobutyraldehyde, and butyral.
SUMMARY OF THE INVENTION
The foregoing procedure can be varied without using benzyl alcohol as the reductant if the vanadium pentoxide is reduced to the desired vanadium tetraoxide by being heated in the presence of a mixture of an alcohol and sufficient phosphoric acid. Even though the reduction of the pentoxide to the tetraoxide is achieved, the catalyst precursor that is precipitated in this system will not be crystalline (VO)2 H4 P2 O9 unless an alkyl silicate is present. When this specific compound is formed, rather than mixed vanadium phosphates, catalysts made from it give butane to maleic anhydride yields of up to about 90%, rather than 50% to 60%.
DETAILED DESCRIPTION OF THE INVENTION
The reduction of the vanadium pentoxide is accomplished in accordance with the instant invention by heating the pentoxide in an appropriate solvent such as an alcohol, e.g., isobutanol, in the presence of a mixture of tetraethylorthosilicate and phosphoric acid. The vanadium pentoxide is preferably in milled form, and the amount of phosphoric acid used should be sufficient (when taken with the later added amount of phosphoric) to give a P/V ratio in the final catalyst of from about 0.9:1 to about 1.3:1.0 as mentioned at Col. 4, lines 21-33, of U.S. Pat. No. 4,632,916. The mixture of vanadium pentoxide, solvent, phosphoric acid, and tetraethylorthosilicate is preferably heated to reflux to achieve the desired degree of reduction.
Then, additional phosphoric acid is added (to achieve the above-stated P/V ratio in the final catalyst) followed by additional refluxing to precipitate the desired crystalline (VO)2 H4 P2 O9 catalyst precursor for a vanadium-phosphorus mixed oxide catalyst.
The Examples which follow set forth in more detail a various embodiments of the claimed invention.
EXAMPLE 1
Approximately 7 lbs of V2 O5 were finely ground through a model JT-6 Fitz mill using a 325 mesh screen with a canvass sock. The milling took place over a period of approximately 15 minutes and the V2 O5 was fed slowly with dry ice.
A 5 liter flask equipped with a heating mantle with variac, stirrer, and reflux condenser was charged with the following ingredients:
______________________________________                                    
Ingredient        Weight (grams)                                          
______________________________________                                    
Isobutanol        2004                                                    
V.sub.2 O.sub.5 (air-dried)                                               
                  250                                                     
Tetraethylorthosilicate                                                   
                  305                                                     
Phosphoric Acid (85%)                                                     
                  160                                                     
______________________________________                                    
The resulting mixture was heated to reflux (about 100C) for approximately 13 hours. Then, the remainder of the 85% phosphoric acid (206 gm) was added. The resulting mixture was refluxed for 6-7 hours with a blue-green precipitate forming during this step.
The resulting reaction mixture was cooled down to close to room temperature and filtered through a 10-15 micron fritted glass filter with vacuum. The product retained by the filter was washed twice with 250 ml of isobutanol and was dried in an oven at 145C and vacuum (20 mm Hg) for eight hours. The product weighed about 490 gm and it was passed through a 100 mesh screen to form a more uniform particle size. The product was confirmed by X-ray diffraction to be a (VO)2 H4 P2 O9 catalyst precursor for a vanadium-phosphorus mixed oxide catalyst. The X-ray diffraction peaks for (VO)2 H4 P2 O9 and their relative intensity (100 =the height of the most intense peak) were:
______________________________________                                    
       20    Rel. Intensity                                               
______________________________________                                    
       30.347                                                             
             100                                                          
       15.481                                                             
             68                                                           
       26.998                                                             
             60                                                           
       19.604                                                             
             43                                                           
       24.098                                                             
             38                                                           
       28.736                                                             
             26                                                           
       31.982                                                             
             23                                                           
       33.667                                                             
             21                                                           
       14.940                                                             
             19                                                           
       33.409                                                             
             15                                                           
       37.328                                                             
             15                                                           
       34.142                                                             
             14                                                           
       39.912                                                             
              9                                                           
       37.136                                                             
              7                                                           
       36.775                                                             
              7                                                           
       35.022                                                             
              6                                                           
       37.637                                                             
              6                                                           
       34.784                                                             
              5                                                           
       36.403                                                             
              5                                                           
       39.620                                                             
              4                                                           
______________________________________                                    
EXAMPLES 2-21
A series of variations were made in the procedure of Example 1 where certain reagents were either present or absent or were changed in some manner. The X-ray diffraction pattern of the resulting product either conformed to that of (VO)2 H4 P2 O9 ("OK") or did not ("NG").
______________________________________                                    
       benzyl                                                             
i-butanol                                                                 
       alcohol  TEOS    V.sub.2 O.sub.5                                   
                               H.sub.3 PO.sub.4 (85%)                     
                                         XRD                              
500 ml (50 ml)  (61 g)  (50 g) 75 g      Data                             
______________________________________                                    
Yes    Yes      Yes     Yes    Yes       OK                               
Yes    No       Yes     Yes    NH.sub.4 CO.sub.3                          
                                         NG                               
Yes    No       Yes     Yes       1 gm   OK                               
Yes    Yes      Yes      200 gm                                           
                               Yes       OK                               
Yes    Yes      Yes     Yes    Yes       OK                               
Yes    Yes      Yes     Yes    Yes       OK                               
Yes    Yes      Yes     Yes    Yes       OK                               
Yes    No       Yes     Yes    Yes       OK                               
Yes    Yes      Yes     Yes    Yes       OK                               
Yes    No       Yes     Yes    Yes       OK                               
Yes    No       No      Yes    100%      NG                               
Yes    Yes      No      Yes    100%      NG                               
2500 ml                                                                   
       250 ml   305 ml  250 ml 375 g     OK                               
2500 ml                                                                   
       No       305 ml  250 ml 375 g     OK                               
Yes    No       No      Yes    100%      NG                               
Yes    No       ethanol Yes    100%      NG                               
Yes    Yes      No      Yes    100%      NG                               
Yes    No       Yes     Yes    Yes       OK                               
Yes    Yes      Yes     Yes    Yes       OK                               
Yes    No       Yes     Yes    Yes       OK                               
______________________________________                                    

Claims (4)

I claim:
1. A process for forming the vanadium-phosphorus-oxide catalyst precursor (VO)2 H4 P2 O9 which comprises reducing milled V2 O5 to V2 O4 by heating the V2 O5 in the presence of an alcohol, an alkyl silicate, and phosphoric acid and precipitating the product with additional phosphoric acid in the presence of the alkyl silicate.
2. A process as claimed in claim 1 wherein at least about 80% of the milled V2 O5 is less than 325 mesh.
3. A process as claimed in claim 1 wherein the alkyl silicate is ethyl silicate.
4. A process as claimed in claim 1 wherein at least 80% of the milled V2 O5 is less than 325 mesh and the alkyl silicate is ethyl silicate.
US07/630,128 1990-12-19 1990-12-19 Preparation of vanadium-phosophorus-oxide catalyst precursor Expired - Fee Related US5108974A (en)

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1082941C (en) * 1993-12-22 2002-04-17 三菱化学株式会社 Process for producing a phosphours-vanadium oxide catalyst precursor, process for producing a phosphorus-vanadium oxide catalyst, and process for producing maleic anhydride by vapor phase oxidation...
WO2004067170A1 (en) * 2003-01-30 2004-08-12 New Tianjin T. & D. Co., Ltd V-p-ci composite oxide catalyst precursor used for producing maleic anhydride from butance
WO2004080131A1 (en) * 2003-03-05 2004-09-16 Alexei Dmitrievich Kanareikin Charge particle beam accelerator
US20060198776A1 (en) * 2005-03-03 2006-09-07 Cross Joseph B Mercury removal sorbent
CN106000434A (en) * 2016-05-23 2016-10-12 刘阳 Maleic anhydride catalyst and preparation method thereof

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4062873A (en) * 1974-12-23 1977-12-13 Chevron Research Company Producing maleic anhydride using certain phosphorous-vanadium-silicon-oxygen containing catalysts
US4382876A (en) * 1980-03-20 1983-05-10 Kurt Neubold Method for producing catalysts for gas phase oxidation of saturated and/or unsaturated C4 -hydrocarbons to maleic anhydride
US4632916A (en) * 1985-07-15 1986-12-30 E. I. Du Pont De Nemours And Company Fumed silica modified catalyst
US4677084A (en) * 1985-11-27 1987-06-30 E. I. Du Pont De Nemours And Company Attrition resistant catalysts, catalyst precursors and catalyst supports and process for preparing same

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4062873A (en) * 1974-12-23 1977-12-13 Chevron Research Company Producing maleic anhydride using certain phosphorous-vanadium-silicon-oxygen containing catalysts
US4064070A (en) * 1974-12-23 1977-12-20 Chevron Research Company Catalyst for producing maleic anhydride
US4382876A (en) * 1980-03-20 1983-05-10 Kurt Neubold Method for producing catalysts for gas phase oxidation of saturated and/or unsaturated C4 -hydrocarbons to maleic anhydride
US4632916A (en) * 1985-07-15 1986-12-30 E. I. Du Pont De Nemours And Company Fumed silica modified catalyst
US4677084A (en) * 1985-11-27 1987-06-30 E. I. Du Pont De Nemours And Company Attrition resistant catalysts, catalyst precursors and catalyst supports and process for preparing same

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1082941C (en) * 1993-12-22 2002-04-17 三菱化学株式会社 Process for producing a phosphours-vanadium oxide catalyst precursor, process for producing a phosphorus-vanadium oxide catalyst, and process for producing maleic anhydride by vapor phase oxidation...
WO2004067170A1 (en) * 2003-01-30 2004-08-12 New Tianjin T. & D. Co., Ltd V-p-ci composite oxide catalyst precursor used for producing maleic anhydride from butance
US20060241310A1 (en) * 2003-01-30 2006-10-26 Renshui Lan V-p-ci composite oxide catalyst precursor used for producing maleic anhydride from butance
US7547655B2 (en) * 2003-01-30 2009-06-16 New Tianjin T. & D. Co., Ltd. V-P-Si composite oxide catalyst precursor used for producing maleic anhydride from butance
WO2004080131A1 (en) * 2003-03-05 2004-09-16 Alexei Dmitrievich Kanareikin Charge particle beam accelerator
US20060198776A1 (en) * 2005-03-03 2006-09-07 Cross Joseph B Mercury removal sorbent
CN106000434A (en) * 2016-05-23 2016-10-12 刘阳 Maleic anhydride catalyst and preparation method thereof

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